Fire-resistant panel systems



Jan. 16, 1968 J. B. DUNNlNGTON 3,364,097

FIRE-RESISTANT PANEL SYSTEMS Filed July 5, 1964 mlumui [MA E INVENTOR. JON B. DUNHINGTOH ffz/ &

United States Patent Ofifice 3,354,097 Patented Jan. 16, 1968 3,364,097 FIRE-RESISTANT PANEL SYSTEMS Jon B. Dunnington, Mercer Island, Wash., assiguor to Weyerhaeuser Company, Tacoma, Wash, a corporation of Washington Filed July 3, 1964, Ser. No. 380,149 8 Claims. (Cl. 161-69) ABSTRACT OF THE DISCLOSURE A fire-resistant panel with cellular pockets forming the core between the panel skins. An infill material having fire-retardant properties, such that it yields its water of hydration upon exposure to elevated temperatures, is contained and supported by the cellular pockets.

Thi invention relates to fire-rated building construction elements and particularly to light wood construction units which are protected in such a manner that they can be used in fire-rated applications.

Light wood construction units can be characterized as those consisting of two external face members with a core member interposed and secured between the faces to form a unitary structure of the three members. One general example of this construction is a unit composed of plywood face members with a cellular honeycomb core member. This structure is referred to as a honeycomb panel, such as the type shown in Us. Patent No. 2,385,352.

A variety of methods and processes is known for making fiameproof or fire-retardant wood products. In general, these methods are based upon impregnation of the wood or wood products with fireproofing agents such as inorganic salts and phosphorous and halogen derivatives, or coating such materials with non-combustible and intnmescent paints to achieve fire-resistive properties. Products so treated provide short term protection under fire exposure due to the small amounts of retardant material added. Thus, they are ineffective and inefiicient barriers and do not satisfy requirements for the length of time necessary to qualify for various fire-rated building umts.

It is the object of this invention to increase the endurance of composite cellular sandwich panel constructions under fire conditions.

It is a further object of this invention to provide protection means which will allow light wood constructions to be used in fire-rated applications.

In the practice of this invention, the space enclosed by each cell of the honeycomb core of a sandwiched panel is utilized as a reservoir for fire retardant chemicals. The voids of the honeycomb are partially filled with granulated borax or a mixture of granulated borax and bark. Both the borax and the borax and bark mixture lose their water of hydration under fire conditions which cools the sandwich panel. The borax, and also the borax and bark mixture, expand and fuse under heat, forming a glass-like surface on the side subjected to the flame, and filling the void spaces to prevent the flame from penetrating to the interior surface of the unexposed panel. Other chemicals having similar characteristics such as organic salts and hydrates of the organic acids and their alkali salts could also be used as a fire-retardant core infill material.

Further objects and advantages of the invention will become more readily apparent from the following description and the annexed drawings. While the invention is susceptible to various modifications, and certain features may be used without the use of other features, certain illustrative panels have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed. On the contrary, the intention is to cover all modifications, alternative constructions, equivalents, and uses falling within the spirit and scope of the invention as expressed in the appended claims.

In the drawings:

FIGURE 1 is an exploded perspective view of a panel unit having a honeycomb core made in accordance with the present invention;

FIGURE 2 is an end elevation view of a panel made in accordance with the present invention, being subjected in a vertical position to a flame test;

FIGURE 3 is a side elevation view of a panel made in accordance with this invention shown in the position required for a horizontal fire test;

FIGURE 4 is a plan view of a fire door constructed in accordance with this invention;

FIGURE 5 is a plan view of a partition panel system, made in accordance with this invention;

FIGURE 6 is a side elevation view of a roof deck system, made in accordance with this invention;

FIGURE 7 is an end elevation View of a tire-rated box beam system made in accordance with this invent-ion; and

FIGURE 8 is a side elevation view of a panel system modification, including relief holes in the interior surfaces of the face members.

With general reference to FIGURE 1, a novel sandwich panel 1 is shown in an exploded perspective view. It is comprised of two face members or skins 3 and 4 and a cellular core 7 having a high degree of void spaces, such as cells 8 and 9 which are used as the container, separator and supporting mechanism for the infill materials 12 which include fire-retardant chemicals. The space in the cellular core 7 is considered a reservoir space into which any beneficial chemical or combination of chemicals can be placed.

The two faces 3 and 4 are bonded to the core 7. Under fire conditions, the resulting composite sandwich panel 1 prevents penetration of the fire to the unexposed face member, for a period of time substantially greater than can be achieved with existing treated or untreated panel systems.

A sample of the structure shown in FIGURE 1 has been subjected to a typical fire-rating test. The core 7 in this sample was one inch thick, consisting of a cellular seventy-eight pound unimpregnated and untreated kraft paper honeycomb, having one inch cell size. The core 7 was bounded to a Mi interior grade plywood face member 3. The honeycomb cells, such as 8 and 9, were filled with a mixture of borax and bark, in this case granular borax and 20% bark which had been well mixed. The density of the mixture 12 was in the range of 40-45 pounds" per cubic foot. The panel unit was then completed by bonding a second face member 4 of A plywood to the core 7. When exposed to elevated temperatures, the core temperature increased slowly, preventing pyrolysis of the unexposed face member 4 for one and one-half hours, while the exposed face member 3 was maintained at a temperature between 1500 to 180Q F.

To be satisfactory, the face members 3 and 4, regardless of specific material, must assist the total assemblage 1 by providing a thermal insulation barrier during fire exposure. The exposed face member 3 should exclude an adequate supply of oxygen at the outset of exposure to reduce degradation. The exposed face member 3 should preferably allow the composite panel 1 to breath just prior to and during the dehydration, decomposition, and volatilization phases of the infill material r12.

3 The unexposed face member 4 must remain intact for the duration of the rated period. It must withstand forces created by fire exposure and a fire hose water stream as well as act as a thermal insulation barrier. The face memmatic form, a composite panel 1 as it would be positioned for a vertical test for fire-rating. As shown the face member 3 is subjected to a flame 1'5 and the core 7 comprises cells such as 8 and 9 which may contain infill material bers 3 and 4 and must also perform the functions of struc- 12 to protect the unexposed face member 4 from the eftural skins under normal conditions. These requirements fects of the flame 15.

are satisfied by cement-asbestos board or plywood, but Referring now to FIGURE 3, a schematic represennot to the exclusion of other facing materials meeting tation of a panel undergoing a horizontal flame test is these general requirements. shown. In a similar manner to that shown in FIGURE 2,

The cellular core material 7 must remain attached to 10 the flame is held in contact with the exposed face memthe inside surface of the unexposed face member 4 during ber 3 and the core 7, consisting of cells such as 8 and 9,

the fire-rated life of the panel assembly 1. The core must contains fire-retardant infill material 12 to protect the contain, hold and support the infill material 12 under fire unexposed face member 4 from the effects of the flame 15.

exposure conditions. It must also provide for discontinu- Several tests have been made on the panel assemblage ity to avoid cracking and assembly warpage. The core 7 15 with variations in the face members, the core member and must also perform the functions of a structural core the type and quantity of the infill material. Table A is under normal conditions. These requirements are satispresented to show the results achieved by panels D, E, F,

fied by both treated and untreated corrugated and cellu- G, and H in the vertical test as shown in FIGURE 2 and lar' paper honeycomb cores. by panels A, B, and C in the horizontal test as shown in A satisfactory infill material 12 may include chemicals FIGURE 3. It should be noted that the flame 15 in both or combinations of chemicals which undergo endothermic the horizontal and vertical tests presents a temperature at reaction at elevated temperatures to act as an absorbers the exposed surface of the exposed skin member 3 beof thermal energy. This material should decompose in tween 1500 and 1800 F. The remaining panels, Ithrough order to absorb thermal energy and form volatile gases U, were subjected to the ASTM E119 Time-Temperature which aid in dissipating the heat. The material should also Fire Exposure Test.

act as a thermal insulator during exposure to thermal While the exact volume of infill material is not critistress without shrinking when heated or flowing away in cal, if there is too little the infill material is unable to molten form. Under normal conditions, the infill material absorb suflicient heat to keep the panel from being con- 12 must be physically and chemically stable. These resumed and if there is too much infill material, it will exquirements are satisfied by the hydrated salts such as pand beyond the limits of the honeycomb and the panel borax (sodium tertabor-ate decahydrate) and carboxylic will erupt. A reasonable range for filling the cells is beacids and their salts which generate carbon dioxide durtween 50 and 90% by volume.

ing thermal decomposition. The following table illustrates the efficacy of the in- Referring now to FIGURE 2, there is shown, in schevention.

TABLE A Panel Skin Members Core Structure Infill Material Test Results A $4" plywood Untreated paper honeycomb None In Horizontal test: Point 5 reached 250 F. with 1" cell size. in 18.5 minutes and 412 F. in 32 minutes at test end.

B do do Each core cell filled with In Horizontal test: Point 5 reached 180 F.

. polyvinyl alcohol (gel form in 30 minutes and maintained that tem- 9095% 1120) perature up to 90 minutes reaching 193 F. I after 120 minutes at test end.

0 $4 plywood w th a 1/16 deep dn ,dn In Horizontal test: Point 5 reached 170 F. hole in both interior in 30 minutes, 180 F. in minutes surfaces opposite each cell maintaining that temperature up to 90 and with alunnnu n foil minutes reaching 186 F. after 120 minseparating each skin from utes at end of test. the core.

D plywood do None In Vertical test: Point 5 reached 250 F. in

14 minutes and 313 F. in 18 minutes at end of test.

E Exposed member 3: 14 .do Each core cell filled with In Vertical test: Point 5 reached 135 F. in plywood with a 1/16 deep polyvinyl alcohol (gel form 30 minutes, 140 F. in 60 minutes, 170 F. hole in its interior surface 90-95% H2O). in 90 minutes, 200 F. in 120 minutes. opposite each cell.

Unexposed member 4: plywood. V

F. do do Each core cell filled with In Vertical test: Point 5 reached 135 F. in mixture of polyvinyl 30 minutes, 135 F. in 50 minutes, 211 F. alcohol (gel form with in minutes, 212 F. in minutes, -95% Hi0) and 50% 350 F. in 79 minutes. bark (by volume).

G do do Each core cell filled with In Vertical test: Point 5 reached 145 F. in borax (sodium tetraborate 30 minutes, 150 F. in 60 minutes, 200 F. decahydrate). in 90 minutes, 250 F. in minutes.

H do do Each core cell filled with In Vertical test: Point 5 reached F. in a mixture of 50% borax and 30 minutes, F. in 60 minutes, F. 50% bark (by volume). in 90 minutes, F. in 120 minutes,

. V 200 F. in 240 minutes.

I do do Each core cell filled with ASTM E119 Test: Unexposed exterior face amixture of boraxand reached 130 F. in 30 minutes, 155 F. bark in a 2%:1 ratio in 60 minutes, 180 F. in 86 minutes, at (by volume). end of test.

I do do Each core cell filled with a ASTM E119 Test: Unexposed exterior face mixture of borax and bark reached 120 F. in 30 minutes, 160 F. in

I in a 3:1 ratio (by volume). 60 minutes, F. in 90 minutes. K plywood 1% block Fire-retardant polystyrenm... ASTM E119 Test: Unexposed exterior face reached 250 F. in 9 minutes, burned I through in 9.25 minutes.

L "do 1%; paper h oneycomo, 11% None ASTM E119 Test: Unexposed exterior face impregnation, cell size. reached 250 F. in 14.5 minutes.

M do 1% block Fire-retardant treated particle ASTM E119 Test: Unexposed exterior face board (sold under the tradereached 250 F. in 56 minutes, burned mark RODDIS through in 45 minutes.

B-Label). N do do Calcium silicate ASTM E119 Test: Unexposed exterior face 7 reached 250 F. in 57 minutes, burned through in 86 minutes.

TABLE AContinued Panel Skin Members Core Structure InfJl Material Test Results do 1% thick paper honeycomb, Each cell filled with a ASTM E119 Test: Unexposcd exterior face 11% impregnation, cell mixture of 80% borax, 18% reached 250 F. in 63.5 minutes, burned size. bark and 2% 0200 through in 66 minutes.

P do do Each cell filled with a ASTM E119 Test: Unexposed exterior face mixture of 60% horax and reached 250 F. in 73.5 minutes, burned 40% bark. through in 75 minutes.

Q Members 3 and 4 both 0.032 do Each cell filled with a ASTM E119 Test: Unexposed exterior face in aluminum sheet. Unmixture of 80% borax reached 250 F. in 82.5 minutes, burned exposedmember 4 had vent (decahydrate) and through in 87 minutes. holes M die. in a 1 grid bark. pattern.

R Members 3 and 4 both 34 do do ASTM E119 Test: Unexposed exterior face cement-asbestos board. Unreached 250 F. in 86 minutes. exposed member 4 had vent holes Me dia. in a 1 grid pattern.

S 24; gypsum board do Each cell filled with a ASTM E119 Test: Uncxposed exterior face mixture of 80% borax, 18% reached 250 F. in 92.5 minutes, burned bark and 2% C3003. through in 100 minutes.

T 0.032 in aluminum sheet 1% block Fire-retardant polystyrene. ASTM E119 Test: Unexposed exterior face reached 250 F. in 5.5 minutes, burned through in 6 minutes.

U Kraft paper Untreated paper honeycomb Each cell filled with a ASTM E119 Test: Unexposed exterior face rhpixkture of 75% borax, burned through in 60 minutes.

From Table A, it is clear from the test results for panel A, that a honeycomb panel unit with plywood skin memhers and without infill material in the cells of the honeycomb is quite unsatisfactory in the horizontal test since the unexposed face member reaches 412 F. in about onehalf hours time. However, in a similar horizontal test using polyvinyl alcohol in gel form in panels B and C with a similar skin and core structure, the point 5 on the unexposed face member 4 reached only 180 F. in one-half hours time maintaining approximately that temperature for over an hour and one-half providing adequate firerated protection.

In the vertical test, as shown in FIGURE 2, panel D, being a hollow honeycomb panel structure, was wholly unsatisfactory after an exposure of a. mere 18 minutes to the flame. However, panel E, being half filled with polyvinyl alcohol in gel form, provided excellent protection for well over ninety minutes in a similar test. Similarly, good results were observed with panels F, G, H, I and I.

Other panels, such as panel K, containing other fireretardant materials between the plywood skins, showed ever poorer results than an empty honeycomb panel. The results with panel L indicate that treating the honeycomb with a fire-retardant impregnation provides little additional protection to the panel structure. Somewhat more satisfactory results were obtained by use of fire-retardant impregnated particle board as shown in panel M which gave satisfactory results up to 45 minutes exposure. A slightly better performance than this was provided by using a solid block of calcium silicate in panel N.

Honeycomb panels with various quantities and mixtures of borax and bark are shown to give excellent results in panels 0, P, Q, R, and S. Even panel U, with kraft paper face members, provided nearly one hour of satisfactory service when the honeycomb core material was filled with a mixture of borax and bark. This is in striking contrast to panel T which utilizes aluminum sheet face members and a solid block of fire-retardant polystyrene which completely failed after a mere 6 minute exposure to the ASTM E119 test.

Thus it is seen that the utilization of the honeycomb core material as a container for fire-retardant infill chemicals provides sufiicient protection for plywood sandwich panels to withstand exposure to fire for extended periods of time.

Variations in the use of the concept of fire-rated panels may be utilized for other construction units such as a fire door shown in FIGURE 4. The door 21 is constructed from fire-retardant styles 22, exterior face members 23 and 24, which may be A; inch plywood, a sandwich core 27 interposed between the two exterior face members,

and an interior structural member 28 may be provided for additional strength.

FIGURE 5 shows a section view of a joint between two partitioned panels 31 and 32, which have exterior face members 33 and 34, which may be quarter-inch plywood, and a sandwich core 37 interposed between the two skin members. The partitioned panels 31 and 32 may be joined by a non-combustible spline member 38 to result in a unified structure, performing various partition system functions.

In FIGURE 6, there is shown a section view of a roof deck .1 comprising structural skin members 42 and 43,

a sandwich core 47 interposed between the skin members and a protected joint 48 positioned Wherever structural support is needed.

In FIGURE 7, there is an end view of a fire-rated box beam 51 having exterior plywood skin members 53, 54, 55 and 56 separated by a sandwich core 57 from plywood web members 58 and flange members 59.

FIGURE 8 discloses a modified panel component 61 having exterior skin members 63 and 64 separated by sandwich core 67. The interior surfaces of skin members 63 and 64 are grooved in areas opposite each cell of the sandwich core 67 to provide vents, such as 68 and 69, for the escaping gases from the cells produced by the infill material 12 when it is subjected to elevated temperatures.

A number of inorganic hydrates, carbonates, and decarboxylating organic acids and their salts have been considered as possible materials to use either alone or in combination with borax to fill fire-resistant honeycomb cores. The results are given in Table A. It has been found that many combinations of chemicals and bark will perform well for sixty minutes, but few will survive for ninety minutes. In general, for filling honeycomb cells, granulated bark (25-15%) and borax (75-85%) appear to be the 'best basic combination to obtain reproducible ninety-minute panel tests. The bark fraction can of course be replaced by wood fragments including sander flour.

Although there is an increase in panel life as the borax content increases, there is a practical limit between and 92% where the pressure build-up within the core causes the 'borax to erupt, causing voids in the core which allow the flame to fall directly onto the otherwise unexposed face member. A certain minimum porosity seems necessary; bark provides this, as well as providing a solid carbon support for the molten borax at high temperatures. The operating principles of the panel construction herein disclosed are not fully understood, but from my observations, they may be best described by the relation of the events which take place during the test for panel fire-resistant life. While this description seems the most likely one, I do not wish to be bound or limited by it. When the flame impinges on the wood face, charring and combustion occur. Within three to eight minutes, the char cracks and the flame from the burning exposed skin member 3 is extinguished. This occurs through the cooling effect of the water of dehydration and the dilution of the combustible products. The charred flame-face 3 then becomes a thermal insulator between the core and the flame. However, the char soon becomes red hot and air oxidation may occur. At this point the heat value of the carbonized wood actually adds fuel to the fire. When the core reaches about 70 C., dehydration of the borax begins to occur. The water from this dissolves some of the borax, forming a hot concentrated solution which impregnates and fireproofs the lignocellulosic faction of the core as well as the interior faces of the veneer.

As the temperatures rise, dehydration of the borax, and the drying of the soaked cellulosic materials absorbs considerable thermal energy. Once the core temperature reaches about 300 C., the core becomes a thermal insulator like an asbestos sheet, since it remains intact as a continuous non-eroding flame barrier. At this stage approximately 60% of the useful thermal absorption capacity of the core is exhausted. During the first stage of dehydration and again when the salt becomes molten, there is considerable mobility in the Wood faces and the core materials become coated with this fireproofing chemical which keeps air from the combustible portions of the panel. If no oxygen can reach the char, no utilization of this potential fuel value will be made.

The thermal absorption eifect is obtained by the additive eifect of several factors. The faces or skins seem to contribute amounts up to or more of the heatabsorbing capacity of the total panel system. By using other face materials such as cement asbestos or combinations of materials, such as veneers or plywoods and cement asbestos boards or sheets, the percentage of heat absorption of the total panel contributed by the faces can be increased.

The infill core materials 12 seem to contribute amounts up to 85% of the heat absorbing capacity of the total panel. This 85% is broken down into the following Ways:

First, the decomposition of the combination of chemicals and absorption of heat by the volatile decomposition products, which in the case of the sodium tetraborate decahydrate apparently amounts to 55% of the total heat absorbing capacity of the core. This step is in itself composed of two major parts, which are the endothermic reaction of dehydration and the absorption of heat by water.

Second, the absorption of the heat by the Water of dehydration and by the volatile products formed from charring of the wood or bark fraction which is about 25% of that contributed by the core.

Third, the heat absorbed by the combination of dehydrated salt and the remaining char which is approximately 15% of the heat absorbing capacity of the core.

The above percentages are stated as approximate values and are not exact for any specific combination of skins, core or infill materials.

Having now described my invention and in what manner the same may be used, what I claim as new and desire to protect by Letters Patent is: V

1. A fire-resistant construction unit comprising in combination:

a pair of confining skin means,

a core means secured to and spaced between said skin means,

said core means embodying a plurality of cellular pocket means,

infill materials having fire-retardant properties, such that they will yield their water of dehydration upon exposure to elevated temperatures, being contained and supported by said core cell pocket means.

2. The construction unit of claim 1 wherein:

said core cell pocket means are filled between 50 and 90% of their volume by said infill materials.

3. The construction unit of claim 1 wherein:

said infill material is polyvinyl alcohol in gel form.

4. The construction unit of claim 1 wherein:

said infill material is borax.

5. The construction unit of claim 1 wherein:

said infill material is a mixture of borax and bark.

6. The construction unit of claim 1 wherein:

said infill material is a mixture of from to borax and from 25 to 15 granulated bark, by volume.

7. A fire-resistant construction system comprising in combination:

first skin means having interior and exterior faces;

second skin means having interior and exterior surfaces and being displaced spacially from said first skin means;

core means spanning the distance between said first and second skin means and having structural components defining cellular pockets secured to both of said interior surfaces;

infill materials having fire-retardant properties, such that they will yield their water of dehydration upon exposure to elevated temperatures, being contained, supported and separated by said core cell pockets.

8. A fire-resistant construction unit comprising in combination:

a pair of plywood skin members,

a core member secured to and spaced between said skin members,

said core member being constructed of paper honeycomb which defines a plurality of cellular pocket means,

each of said cellular pocket means being filled from 50 to by volume, by an infill material,

said infill material being a mixture of from 75 to 85% borax and from 25 to 15% bark, by volume,

said infill material being contained, supported and separated by said pocket means.

References Cited UNITED STATES PATENTS 2,690,100 9/1954 McGarvey 161403 X 3,043,730 7/1962 Adie 161123 X 3,210,147 10/1965 Johnson et al 117136 X 2,385,352 9/1945 Davis 156156 3,114,840 12/1963 Johnston 161-87 X FOREIGN PATENTS 501,768 4/1954 Canada. 543,740 7/1957 Canada.

EARL M. BERGERT, Primary Examiner.

H. F. EPSTEIN, Assistant Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,364,097 January 16, 1968 Jon B. Dunnington It is certified that error appears in the above identified patent and that said Letters Patent are hereby corrected as shown below:

Column 2, line 39, "faces 3 and 4" should read faces, 3 and 4 line 50, "bounded" should read bonded Column 3, line 22, "absorbers" should read absorber Column 7, line 7, "dehydration" should read hydration line 52, "dehp" should read hy line 63, "as" should read is Column 8, lines 6 and 33, "dehydration", each occurrence,

should read hydration Signed and sealed this 5th day of August 1969.

(SEAL) Attest:

Edward M. Fletcher, Jr.

Attesting Officer Commissioner of Patents WILLIAM E. SCHUYLER, JR. 

